Tubular induction coil for wireless charging of a vehicle battery

Abstract

An induction coil for wireless charging of a vehicle battery is described. The induction coil includes an electrically conductive tube configured as multiple windings, and an electrically conductive coupler configured for attachment to the electrically conductive tube. The electrically conductive tube and the electrically conductive coupler are adapted to conduct an alternating current. Alternating current flow in the tube and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery. The electrically conductive tube and the electrically conductive coupler are each configured for passage of a coolant therethrough. A coolant flow through the electrically conductive tube transfers heat from the electrically conductive tube generated by alternating current flow through the electrically conductive tube.

What is claimed is: 
     
       1. An induction coil for wireless charging of a vehicle battery, the induction coil comprising:
 an electrically conductive tube configured as a plurality of windings; and 
 an electrically conductive coupler configured for attachment to the electrically conductive tube; 
 wherein the electrically conductive tube and the electrically conductive coupler are to conduct an alternating current, wherein alternating current flow in the tube and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery; and 
 wherein the electrically conductive tube and the electrically conductive coupler are each configured for passage of a coolant therethrough, wherein a coolant flow through the electrically conductive tube transfers heat from the electrically conductive tube generated by alternating current flow through the electrically conductive tube. 
 
     
     
       2. The induction coil of  claim 1  further comprising an electrically insulative material on an outer surface of the electrically conductive tube. 
     
     
       3. The induction coil of  claim 2  further comprising another electrically conductive tube on an outer surface of the electrically insulative material, wherein the electrically conductive coupler is further configured for attachment to the another electrically conductive tube. 
     
     
       4. The induction coil of  claim 3  further comprising another electrically insulative material on an inner surface of the electrically conductive tube. 
     
     
       5. The induction coil of  claim 3  wherein the electrically insulative material comprises an oxide, varnish, paint, polymeric coating, polymer tube, heat shrink tube, or an electrically insulative fluid. 
     
     
       6. The induction coil of  claim 3  wherein the electrically conductive tube, the electrically insulative material, and the another electrically conductive tube have a circular cross-section and the electrically conductive coupler comprises a ring having a first annular feature configured to receive an end of the electrically conductive tube and a second annular feature configured to receive an end of the another electrically conductive tube. 
     
     
       7. The induction coil of  claim 6  wherein the electrically conductive coupler comprises a first end and a second end, the first end having the first and second annular features, and the second end configured for attachment to an another tube configured to supply the coolant. 
     
     
       8. The induction coil of  claim 7  wherein the second end of the electrically conductive coupler comprises a third annular feature configured to receive an end of the another tube configured to supply the coolant. 
     
     
       9. The induction coil of  claim 1  wherein the electrically conductive coupler comprises an attachment feature for attachment to an electrical conductor. 
     
     
       10. The induction coil of  claim 1  wherein the plurality of windings is configured in a plane. 
     
     
       11. The induction coil of  claim 1  wherein the plurality of windings is configured for assembly with a pad configured for attachment to a vehicle or a charging station. 
     
     
       12. An induction coil for wireless charging of a vehicle battery, the induction coil comprising:
 a first electrically conductive tube; 
 a second electrically conductive tube inside the first electrically conductive tube and coextensive therewith, wherein the first and second electrically conductive tubes are configured as a plurality of windings; 
 a first electrically insulative material between the first and second electrically conductive tubes; and 
 an electrically conductive coupler configured for attachment to the first electrically conductive tube, wherein the electrically conductive coupler comprises an attachment feature for attachment to an electrical conductor; 
 wherein the first and second electrically conductive tubes and the electrically conductive coupler are to conduct an alternating current, wherein alternating current flow in the first and second electrically conductive tubes and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery; and 
 wherein the second electrically conductive tube is configured for passage of a coolant therethrough, wherein a coolant flow through the second electrically conductive tube transfers heat from at least the second electrically conductive tube generated by alternating current flow through the second electrically conductive tube. 
 
     
     
       13. The induction coil of  claim 12  further comprising a second electrically insulative material on an inner surface of the second electrically conductive tube. 
     
     
       14. The induction coil of  claim 12  wherein the first electrically conductive tube, the first electrically insulative material, and the second electrically conductive tube have a circular cross-section and the electrically conductive coupler comprises a ring having a first annular feature configured to receive an end of the first electrically conductive tube and a second annular feature configured to receive an end of the second electrically conductive tube. 
     
     
       15. The induction coil of  claim 14  wherein the electrically conductive coupler has a first end and a second end, the first end comprising the first and second annular features, and the second end configured for attachment to an end of another tube configured to supply the coolant. 
     
     
       16. The induction coil of  claim 15  wherein the second end of the electrically conductive coupler comprises a third annular feature configured to receive the end of the another tube configured to supply the coolant. 
     
     
       17. The induction coil of  claim 12  wherein the plurality of windings is configured for assembly with a pad configured for attachment to a vehicle or a charging station. 
     
     
       18. The induction coil of  claim 12  wherein the first and second electrically conductive tubes are configured as the plurality of windings by bending the first and second electrically conductive tubes. 
     
     
       19. A method of manufacturing an induction coil for wireless charging of a vehicle battery, the method comprising:
 forming a first electrically conductive tube, a second electrically conductive tube, and an electrically insulative material into a concentric tube structure, wherein the second electrically conductive tube is inside the first electrically conductive tube, and wherein the first electrically insulative material is between the first and second electrically conductive tubes and electrically isolates the first electrically conductive tube from the second electrically conductive tube; and 
 bending the concentric tube structure to form a plurality of windings, wherein the first and second electrically conductive tubes are to conduct an alternating current, wherein alternating current flow in the first and second electrically conductive tubes and the plurality of windings generates a magnetic field for wireless inductive charging of the vehicle battery, wherein the concentric tube structure is configured for passage of a coolant therethrough, and wherein a coolant flow through the tube structure transfers heat from at least the second electrically conductive tube generated by alternating current flow in the second electrically conductive tube. 
 
     
     
       20. The method of  claim 19  further comprising attaching an electrically conductive coupler to the concentric tube structure, the electrically conductive coupler comprising an attachment feature for attachment to an electrical conductor.